SUBJECT PART NAME MATERIAL PURPOSE

: : : :

PACKAGING STUDY 601A DOOR TRIM PART

COVER RECLINING ADJUSTER INSIDE

DELLOYD INDUSTRIES (M) SDN BHD PRODUCTION ENGINEERING DEPARTMENT SOLUTION DEVELOPMENT SHEET

Prepared

Verified

AMALINA

ZAMRI ISA DATE:

Page: 1 of

DATE: 3/6/2011

Volume forecast for 2 years = 1920 carset/month x 1 pc/carset x 12 month/year x 2 years

46080

pcs (Z)

NO.

ITEM Polybox contain 60 pcs parts # Total Part for 1 day [320 pcs x 2pcs/carset)/22 day] # Total Polybox for 1 day # Total Polybox for 1 day x 10% allawonce

Cost (RM) 60 87 1.45 2 3 5 5.00 3.00 110.00 38.40 0.10 8 0.80 3.20 15.36 500.00 2 1.26 5.05 24.24 Box Piece

A B C

Esttimed stock for 3 days # Total Polybox for 3 day

D=C*3 E AA

3 4 5 7 8

Cost of Nesting set Eva Foam Size (LxW) - 1m x 2m x 2mm (t) 1 Polybox Total cost for Nesting & Foam (5 polybox) Est 1 rivet Total rivet per box (8) # Cost rivet per box # Total Cost rivet per box for 4 time change # Total rivet cost for 2 polybox

AV=N+O+AR+AS+AT+AU P Q R=P*Q R1=R*4 R2=R1*D S T U=S(22*9*T) U1=U*4 U2=U2*D V=AV*2 W=V*2 X=R2+U2+W Y=X/Z

Est salary for general worker (9 hours a day, 22 days/month) 1 worker can complete 2 polybox within an hour # Cost for labor per box # Total Cost for labor per box for 4 time change # Total labor cost for 2 polybox

10 Lifespan of nesting and foam is estimated to be 6 month Nesting and foam needed to be fabricated twice per year Amortization = 2 years # Total Nesting and foam cost for 2 years (5 polybox) 11 Total Packaging Cost 12 Average cost per pc 153.60 303.20 0.0066 76.80

REMARKS:

PE/002/01

SUBJECT PART NAME MATERIAL PURPOSE

: : : :

PACKAGING STUDY 601A DOOR TRIM PART

COVER RECLINING ADJUSTER INSIDE

DELLOYD INDUSTRIES (M) SDN BHD PRODUCTION ENGINEERING DEPARTMENT SOLUTION DEVELOPMENT SHEET

Prepared

Verified

AMALINA

ZAMRI ISA DATE:

Page: 1 of

DATE: 3/6/2011

Volume forecast for 2 years = 920 carset/month x 2 pc/carset x 12 month/year x 2 years

44160

pcs (Z)

NO.

ITEM Polybox contain 60 pcs parts # Total Part for 1 day [920 pcs x 2pcs/carset)/22 day] # Total Polybox for 1 day # Total Polybox for 1 day x 10% allawonce

Cost (RM)

84 2 3

A B C

Esttimed stock for 3 days # Total Polybox for 3 day 9 18.00 95 0.1895 85 0.2118 4 0.7579 2 0.4235

D=C*3 E F G=E/F H I=E/H J K=J*G L M=L*I

PP Corrugated Size (LxW) - 4' x 8' x 4mm (t) 1.1) Nesting A - 1 sheet of PP Corrugated can produce 951 pcs # Cost per pc of nesting A 1.2) Nesting B - 1 sheet of PP Corrugated can produce 852 pcs # Cost per pc of nesting B 1.3) 1 box requires 4 pcs Nesting A # Cost for Nesting A per box 1.4) 1 box requires 2 pcs Nesting B # Cost for Nesting B per box

1 Polybox requires 4 pcs Nesting A & 2 pcs of Nesting B # Total Cost for Nesting A (2 polybox) # Total Cost for Nesting B (2 polybox) 6.82 3.8118 16.00 0 0.00 0 0.00 0 0.00 0 0.00

N=K*D O=M*D AA AB AC=AA/AB AD AE=AA/AD AJ AK=AC*AJ AL AM=AE*AL

Eva Foam Size (LxW) - 1m x 2m x 2mm (t) 2.1) 1 sheet of Eva Foam can produce 12 pcs of Foam A # Cost per pc of foam A 2.2) 1 sheet of Eva Foam can produce 40 pcs of Foam B # Cost per pc of foam B 2.5) 1 box requires 1 pcs Foam A # Cost for Foam A per box 2.6) 1 box requires 2 pcs Foam B # Cost for Foam B per box

1 Polybox requires pcs for Foam # Total Cost for Foam A (2 polybox) # Total Cost for Foam B (2 polybox) 0.00 0.00 10.63 0.10 8 0.80 3.20 28.80 500.00 2 1.26 5.05 45.45

AR=AK*D AS=AM*D AV=N+O+AR+AS+AT+AU P Q R=P*Q R1=R*4 R2=R1*D S T U=S(22*9*T) U1=U*4 U2=U2*D V=AV*2 W=V*2 X=R2+U2+W Y=X/Z

7 8

Total cost for Nesting & Foam (2 polybox) Est 1 rivet Total rivet per box (8) # Cost rivet per box # Total Cost rivet per box for 4 time change # Total rivet cost for 2 polybox

Est salary for general worker (9 hours a day, 22 days/month) 1 worker can complete 2 polybox within an hour # Cost for labor per box # Total Cost for labor per box for 4 time change # Total labor cost for 2 polybox

10 Lifespan of nesting and foam is estimated to be 6 month Nesting and foam needed to be fabricated twice per year Amortization = 2 years # Total Nesting and foam cost for 2 years (27 polybox) 11 Total Packaging Cost 12 Average cost per pc 42.53 116.79 0.0026 21.27

REMARKS:

PE/002/01